Alfalaval Unique SSV PN10 User manual

ESE00202-EN9 2015-04
Original manual
Instruction Manual
Unique Single Seat Valve - Standard and Reverse Acting

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 8
3.1. Unpacking/delivery ............................................................................... 8
3.2. General installation ................................................................................ 10
3.3. Welding ............................................................................................ 11
3.4. Recycling information ............................................................................. 12
4. Operation ............................................................................................... 13
4.1. Operation .......................................................................................... 13
4.2. Troubleshooting ................................................................................... 14
4.3. Recommended cleaning ......................................................................... 15
5. Maintenance ........................................................................................... 16
5.1. General maintenance ............................................................................. 16
5.2. Dismantling the valve ............................................................................. 18
5.3. Plug seal replacement ............................................................................ 19
5.4. Assembly of valve ................................................................................. 19
5.5. Actuator bushing replacement .................................................................. 20
5.6. Dismantling of optional maintainable actuator ................................................. 25
5.7. Mounting of optional maintainable actuator .................................................... 25
5.8. Additional equipment ............................................................................. 25
6. Technical data ......................................................................................... 26
6.1. Technical data ..................................................................................... 26
7. Parts list and service kits ............................................................................ 27
7.1. Drawing ............................................................................................ 27
7.2. Unique Single Seat Valve - Shut-off Valve ...................................................... 28
7.3. Unique Single Seat Valve - Change-over Valve ................................................ 30
7.4. Drawing ............................................................................................ 33
7.5. Unique Single Seat Valve Reverse Acting - Shut-off Valve .................................... 34
7.6. Unique Single Seat Valve Reverse Acting - Change-over Valve .............................. 36
7.7. Maintainable actuator ............................................................................ 38
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval KoldingA/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
Unique SSV PN10
Type
From serial number 5099880 to 29999999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
The person authorised to compile the technical file is the signer of this document
QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name
Kolding 2013-12-03
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
2.1 Important information
Always read the manual before using the valve!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the valve.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Caustic agents:
5

2 Safety
All warnings in this manual are summarised on this page.
Pay special attention to this instructions below so that severe personal injury and/or damage to the valve are avoided.
2.3 Safety precautions
Actuators marked with year 2012 (new actuator
design):
Alfa Laval recommends not to exceed 3 bar support air
onthespringsideinalltheUniqueSSVactuators,to
ensure 10 bar product pressure without leakage. Alfa Laval recommends max. 3 bar
Plastic adapter (pos. 5) is always used on the new
design.
ø157.5 mm
TD 461-990
5
Actuators marked with year 2006-2011 (old actuator
design):
WARNING! Max. 3 bar “support air” on spring side.
When using “support air” on spring side in all the Unique
SSV actuators, the pressure must NOT exceed 3 bar.
When using Unique SSV actuators with ø156mm with
support air, always use the “steel adapter” (pos. 5).
Tighten the “steel adapter” to a torque of 30 Nm and
use Loctite 243.
ø156 mm
The actuator with ø156mm is mainly used on valves
ISO76/DN80 – ISO101/DN100. The outer actuator
diameter = ø156 mm.
TD 461-990
5
6

2 Safety
All warnings in this manual are summarised on this page.
Pay special attention to this instructions below so that severe personal injury and/or damage to the valve are avoided.
Installation:
Always read the technical data thoroughly (see chapter 6 Technical data)
Always release compressed air after use
Never touch moving parts if the actuator is supplied with compressed air
Never touch the valve or the pipelines when processing hot liquids or when sterilising
Never dismantle the valve with valve and pipelines under pressure
Never dismantlethevalvewhenitishot
Operation:
Never dismantle the valve with valve and pipelines under pressure
Never dismantlethevalvewhenitishot
Always read the technical data thoroughly (see chapter 6 Technical data)
Always release compressed air after use
Never touch the valve or the pipelines when processing hot liquids or when sterilising
Never touch moving parts if the actuator is supplied with compressed air
Always rinse well with clean water after cleaning
Always handle lye and acid with great care
Maintenance:
Always read the technical data thoroughly (see chapter 6 Technical data)
Always release compressed air after use
Never servicethevalvewhenitishot
Never service the valve with valve and pipelines under pressure
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Never touch moving parts if the actuator is supplied with compressed air
Transportation:
Always ensure that compressed air is released
Always ensure that all connections are disconnected before attempting to remove the valve from the installation
Always drain liquid out of valves before transportation
Always use predesigned lifting points if defined
Always ensure sufficient fixing of the valve during transportation - if specially designed packaging material is available,
it must be used
7

3 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The items refer to the parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve, shut off valve (RA) or change-over
valve (RA) (see steps 2a, 2b, 2c and 2d).
2. Delivery note.
Step 2
2a
Shut-off valve:
1. Complete actuator.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
2b
Change-over valve:
1. Complete actuator.
2. Bonnet (20).
3. 2 x clamps (19).
4. Valve plug (27).
5. Lower valve body (22).
6. Valve seat (28).
7. Upper valve body (26).
UP
TD 461-020_1
2c
Shut-off valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 3 x clamps (19).
4. Valve plug (23).
5. 2 x upper valve bodies (26).
6. Valve seat (28).
7. Lower bonnet (33).
UP
TD 461-021_1
8

3 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The items refer to the parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
2d
Change-over valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 4 x clamps (19).
4. Upper valve plug (34).
5. Lower valve plug (35).
6. 3 x upper valve bodies (26).
7. 2 x valve seats (28).
8. Lower bonnet (33).
UP
TD 461-022_1
Step 3
Remove possible packing materials from the valve/valve parts.
Inspect the valve/valve parts for visible transport damage.
Avoid damaging the valve/valve parts.
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
3.2 General installation
Step 1
Always read the technical data thoroughly. See chapter 6 Technical data.
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Never touch moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
Step 3
To avoid water hammer, it is recommended to install the valve so
that the flow is against the closing direction.
Shock in the actuator must never occur.
Avoid water
hammering!
Inlet
Inlet
Step 4
Avoid stressing the valve.
Pay special attention to:
-Vibr
ations.
-The
rmal expansion of the pipelines.
-Exc
essive welding.
-Ove
rloading of the pipelines.
Risk of damage!
10

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.3 Welding
Step 1
Always install valves with more than one valve body so that the
seals between the valve bodies can be replaced. Do not weld
more than one valve body into the system.
Valve size A (mm) B (mm)
DN25/25 mm * 630
DN40/38 mm * 700
DN50/51 mm * 750
DN65/63.5 mm * 740
DN80/76 mm * 800
DN100/101.6 mm * 790
* Depending on body combination and piping solution.
B (incl. top unit)
A*
Step 2
Assemble the valve in accordance with the steps on page 19.
Pay special attention to the warnings!
Step 3
Pre-use check:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to ensure that it
operates smoothly.
Pay special attention to the warnings!
Air
Air
Open/close!
11

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.4 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be re-used, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling
• Maintenance
- During maintenance, oil and wearing parts in the machine are replaced
- All metal parts should be sent for material recycling
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling
- Oil and all non-metal wear parts must be disposed off in agreement with local regulations
• Scrapping
- At end of use, the equipment must be recycled according to the relevant, local regulations. Besides the equipment itself,
any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or
in the absence of local regulations, please contact your local Alfa Laval sales company
12

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
4.1 Operation
Step 1
Always read the technical data thoroughly. See chapter 6 Technical data.
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect operation.
Step 2
Never touch the valve or the pipelines when processing hot
liquids or when sterilising. Danger of burns!
Step 3
Never touch moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
Step 4
Lubrication of valves:
1. Ensure smooth movement between lip seal (25) and
plug stem (23, 27).
2. Lubricate with Klüber Paraliq GTE 703 if necessary
(see page 16).
Shut-off valve Change-over valve
13

4Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the parts list and service kits section.
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate with Molykote Longterm 2 plus if necessary.
4.2 Troubleshooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts - see page 16.
Problem Cause/result Repair
External product leakage Worn or damaged lip
seal and/or O-ring
- Replace the seals
- Replace with seals of a
different rubber grade
Internal product leakage - Worn or product affected
plug seal - Replace the seal - Replace with a seal of a
different rubber grade
- Product deposits on
the seat and/or plug - Frequent cleaning
- Product pressure exceeds
actuator specification - Replace with a high pressure actuator - Use auxiliary air on the spring side
(do not exceed 3 bar). See 2.3 Safety
precautions
- Reduce product pressure
Water hammer The flow direction is the
same as the closing direction
- The flow direction should be
against the closing direction
- Throttle air release of solenoid in
top unit
The valve does not
open/close
Product pressure exceeds
actuator specification
- Replace with a high pressure actuator
- Use auxiliary air on the spring side
- Reduce product pressure
14

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
4.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use
rubber gloves!
Always use
protective goggles!
Step 2
Never touch the valve or the pipelines when sterilising.
Danger of burns!
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings
Lift and lower valve plug momentarily!
Shut-off valve Change-over valve
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC2.0.5%byweightHNO
3at 70oC
1kg
NaOH +100 l water =Cleaning agent. 0.7 l 53% HNO3+100 l
water =Cleaning agent.
2.2 l
33% NaOH +100 l water =Cleaning agent.
Step 5
1. Avoid excessive concentration of the cleaning agent.
2. Adjust the cleaning flow to the process.
3. Always rinse well with clean water after the cleaning.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Clean water Cleaning agents
15

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
Check the valve for smooth operation after service.
5.1 General maintenance
Step 1
Always read the technical data thoroughly. See chapter 6 Technical data.
Always release compressed air after use.
NOTE
All scrap must be stored/discharged in accordance with current regulations/directives.
Step 2
Never service the valve when it is hot.
Never service the valve with valve and pipelines under pressure.
Atmospheric
pressure
required!
Danger of burns!
Step 3
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air
Danger of cuts!
Air
Step 4
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
16

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
Check the valve for smooth operation after service.
Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal
working conditions in one shift.
Product wetted seals Actuator bushings complete
Preventive
maintenance
Replace after
12 months depending
on working conditions
Replace after
5 years depending
on working conditions
Maintenance after
leakage (leakage
normally starts slowly)
Replace at the
end of the day
Replace when
possible
Planned
maintenance
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the valve
- Use the statistics for
inspection planning
Replace after leakage
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the actuator
- Use the statistics for
inspection planning
Replace after leakage
Lubrication
Before fitting
Klüber Paraliq GTE 703
or similar USDA H1
approved oil/grease
Before fitting
Molykote Longterm 2 plus
Pre-use check: Air
Open/close!
1. Supply compressed air to the actuator.
2. Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Air
Recommended spare parts
Servicekits(seepage27)
17

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
5.2 Dismantling the valve
Step 1
1a
Shut-off valve:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove clamp.
3. Release compressed air (only NC).
4. Lift away the actuator.
5. Unscrew and remove valve plug.
6. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings! TD 461-959
Note!
Be careful not to damage the
bushing.
Note! For plug seal replacement see page 19.
1b
Change-over valve:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove lower clamp.
3. Release compressed air (only NC).
4. Lift away the actuator and upper valve body.
5. Supply compressed air to the actuator (only NO).
6. Unscrew and remove valve plug.
7. Release compressed air (only NO).
8. Remove seat and O-rings.
9. Loosen and remove upper clamp.
10. Remove upper valve body.
11. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet.
See drawing, step 1a).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings!
Note! For plug seal replacement please see page 19.
UP
TD 461-044_2
1c
Shut-off valve - Reverse Acting:
1. Loosen and remove lower clamp.
2. Remove lower bonnet and O-ring from lower body.
3. Loosen and remove middle clamp.
4. Lift away the actuator and upper valve body.
5. Supply compressed air to the actuator (only NC).
6. Unscrew and remove valve plug.
7. Release compressed air (only NC).
8. Remove seat and O-rings.
9. Loosen and remove upper clamp.
10. Remove upper valve body.
11. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet.
See drawing, step 1a).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings!
Note! For plug seal replacement please see page 19.
UP
TD 462-004_2
UP
18

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
1d
Change-over valve - Reverse Acting:
1. Loosen and remove lower clamp.
2. Remove lower bonnet and O-ring.
3. Loosen and remove clamp between lower and middle
valve body.
4. Lift away the actuator and upper + middle valve body.
5. Supply compressed air to the actuator (only NC).
6. Unscrew and remove lower valve plug.
7. Release compressed air (only NC).
8. Remove lower seat and O-rings.
9. Supply compressed air to the actuator (only NO).
10. Loosen and remove clamp between middle and upper
valve body.
11. Remove middle valve body and upper seat with O-rings.
12. Release compressed air (only NO).
13. Loosen and remove upper clamp.
14. Remove upper valve body.
15. Unscrew and remove upper valve plug.
16. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet. See drawing, step
1a).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings!
Note! For plug seal replacement please see page 19.
UP
UP
TD 462-003_2
UP
5.3 Plug seal replacement
1. Remove old seal ring using a knife, screwdriver or similar.
Be careful not to damage metal parts.
2. Pre-mount plug seal without pressing it into the groove.
3. Squeeze plug seal into the groove using opposite pressure points.
4. Release compressed air behind plug seal.
Note! For plug seal replacement please read instruction in service kit.
5.4 Assembly of valve
Reverse order of 5.2 Dismantling the valve.
Lubricate O-ring (21) and lip seal (25) with Klüber Paraliq GTE 703.
Remembertotightenspindleandplugtoatorqueof30Nm(tousetwo17mmspanners)
If there are vibrations in the pipeline, Alfa Laval recommends the using of Loctite no. 243.
19

5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section. Handle scrap correctly.
A/A = Air/air activated.
Service tool: See spare parts.
5.5 Actuator bushing replacement
Step 1
Introduction
- The actuator service kit contains two bushings and four o-rings.
- Mount the thick o-ring inside and the thin o-ring outside the
bushing.
- Always lubricate the spindle and o-rings thoroughly with
“Molykote LongTerm 2 Plus” before mounting the new
bushings.
2200-0000
Step 2
Introduction - Standard socket wrench
Use a 27 mm socket wrench to mount the bushings, as the space in the yoke is limited.
A socket wrench 24x27 (length = 185 mm) is a standard tool, which can be purchased from all tool shops.
A=185mm
2200-0001
A
Example:
Socket wrench - 24x27 mm
Supplier: Gedore Tool
EAN4010886621264
2200-0002
20